Method of manufacturing housing module gable

ABSTRACT

An edge beam construction including two vertical perforated rolled shapes with webs inverted toward the center of the beam, and a bottom track having a flange disposed in a vertical position against bottom lips of the vertical rolled shapes. The three basic components of the edge beam are positioned so as to provide access for press joining tools. A building module manufacturing method utilizes the light gauge steel rolled shapes that permit industrialized, automated manufacture of floor, roof and wall panels for modular housing and commercial structures with integrated mechanical and electrical systems and rigid framing for road transport without trailers. The module manufacturing method includes a novel method of constructing and positioning a gable.

This is a divisional application of Ser. No. 11/516,661, filed Sep. 7,2006, which claims the benefit of U.S. Provisional Application No.60/714,371, filed Sep. 7, 2005, the entire contents of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a novel method of industrial, automatedmanufacture of light gage steel floor, roof and wall panels, withexceptional energy properties, to form stronger building modules ofvarying width, height and length. The invention provides structures ofone to four stories for homes, offices, motels, hotels and othercellular structures. The method also allows aesthetic flexibility for awide range of products, from traditional family home designs tocontemporary structures including large glass surfaced areas and spatialelements. The invention uses lighter weight materials; thereby reducingmodule weight by approximately 40% of modules produced by the currentwood modular industry and significantly reduces shipping costs from themanufacturing plant to the erection site.

2. Description of the Related Art

The intent of the modular industry is to provide a finished, qualityhousing product in the shortest amount of time. However, the currentmodular industry has not yet achieved full integration of mechanical andutility services as part of an automated production system and is stillreliant upon labor intensive technology, historic materials and outdatedmodes of structural framing. There is vast improvement possible in allstages of module construction, transport and erection.

In addition to requiring weeks to finish a typical 2,000 ft² house, theindustry wastes time and money with outmoded transport methods. Forinstance, the major structural elements of modular construction arelongitudinal members, which support transverse joists to create thefloor panel of the module. The industry usually locates the members ineither the field of the panel to allow the transverse joists tocantilever to the outside width dimension of the module or as a framefor floor panels with joists extended to the inside of perimeter woodbeams that support the module during crane erection at the site. Thesecond method requires expensive, heavy steel framed multi-axletransport trailers to limit damage to gypsum and other relatively softinterior finishes due to module flexion during transport.

Currently the industry standard is far from the ideal product of acomplete module including integrated mechanical and utility services,full insulation and efficient use of materials. Although certain modularindustry products approximate the ideal, the mainstream modular industryhas developed without the structural, cost and aesthetic advantage ofgalvanized light gage steel rolled shapes and automated productiontechnologies.

Despite the potential, light gauge steel has not historically beeneconomical primarily due to difficult connection problems. Theattachment of light gauge steel shapes to construct panels for modularstructures, limited by national codes and conventions that adhere tohistoric structural configurations and fastening details, fails to takeadvantage of the inherent strength of light gauge steel materials. Thegalvanized surface that protects steel from rust and corrosion limitsthe use of welding attachment due to the toxic gas emitted during thewelding process. The use of screw and nailing attachment of the membersused to construct onsite structures is labor intensive and does not lenditself to either the multiple directions required of application toolsin fastening multiple members or the creation of complex compositestructural configurations needed to develop the strength capabilities oflight gauge steel rolled shape members.

Recent advances in fastening technology promise an economical solutionfor jointing of light gauge steel. Press joining of light gage metalswas introduced in Europe in the late 1980's, tested and proven, andsince, tested and approved by most of the building codes in the UnitedStates. The activation of the press joint is fast, inexpensive andprovides proven consistent joint strength for light gauge steel.However, the press joining tools, which can provide fastening of lightgage galvanized steel sheets, are bulky and do not lend themselves tomulti flexible positioning required for complex designs and difficult toreach members of complex composite designs. These problems must besolved before the press joining technology is introduced for automatedmodule fabrication.

The historic structural configurations preferred and included in today'scodes are based on labor intensive materials and hand held tools, whichdo not lend themselves to automation and the use of press joiningfastening. Limited by current technology, the modular industry has notadvanced beyond outdated models and modes of production. The object ofthe invention is to incorporate two technologies; light gage galvanizedrolled structural shapes and the press joining technology, in anautomated module manufacturing system by inventing new structuralconfigurations and procedures which build upon the assets of eachtechnology to create 21^(st) century structures.

SUMMARY OF THE INVENTION

To accomplish automation in plant manufacture of light gage steelmodular structures, it was necessary to invent structural combinationsand configurations of standard light gage rolled shapes that provide thebulky press joining tools access to the members being joined forcomplete fastening of both single and multi light gage steel members.Understanding that this is not always possible, robotics provided withthermal force feedback (TFF) with resistance welding will supplement thepress joining technology in areas of limited accessibility.

The invention uses floor panel edge beams herein referred to as EB's toachieve a triplicate function; mechanical & utility distribution,integral longitudinal structure to receive axles and wheels forshipping, and longitudinal edge beams for crane lifting and boltingand/or mechanically splicing the modules together to create a housingmodule.

Perforated rolled shapes used in both the transverse and longitudinaldirection of the floor, ceiling, and roof panels, and the verticalexterior and marriage walls of the modules perform the multi-function ofenergy conservation and distribution of mechanical, plumbing, andelectrical access to transfer services within and between the modulescomposing the structure. The invention reduces thermal conductance byemploying standard multi-perforated open web rolled shapes manufacturedby several companies to minimize energy transfer to and from the outsidethrough the structural system. Also, the perforated rolled shapes offerconnection points for transport assemblies, thereby eliminating the needfor costly transport trailers.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing and other objects of the invention will become more clearfrom the following detailed description of a preferred embodiment of theinvention taken in conjunction with the drawings wherein:

FIG. 1A is a top plan view of an edge beam constructed in accordancewith the present invention;

FIG. 1B is a side view of the edge beam illustrated in FIG. 1A;

FIG. 1C is a side view showing the connections of load-bearing andnon-load bearing studs to an edge beam;

FIG. 2 shows sectional views of various edge beams taken at a connector;

FIG. 3 is a plan view showing approximate edge beam and transversemember locations for a typical floor panel, similar to a typical ceilingpanel framing scheme;

FIG. 4 is a plan view showing a typical exterior and marriage wallframing scheme;

FIG. 5 is a plan view showing a typical interior wall framing scheme;

FIG. 6A is a perspective view of an edge beam provided with a lightgauge steel framing connector;

FIG. 6B is an end view of the edge beam and light gauge steel framingconnector shown in FIG. 6A;

FIG. 6C is a side view of the edge beam and light gauge steel framingconnector shown in FIG. 6A;

FIGS. 7A-C are schematic illustrations of transport assembly mountingdetails for attachment to a modular frame;

FIG. 8 is a drawing showing assigned areas in the plant for eachproduction stage;

FIG. 9 is a drawing showing an overview of the plant layout; and

FIGS. 10A-K are a series of drawing figures illustrating a gablepositioning procedure.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIGS. 1A to 1C, an edge beam (EB) (3) is constructed of twovertical perforated rolled shapes (1 a, 1 b) having webs that areinverted toward the center of the beam and one bottom track (2) with theflanges in a vertical position against the bottom lips of the verticalrolled shapes. The two vertical members and the bottom track compose aU-shaped edge beam (3) having an open top to permit the insertion ofmechanical and utility distribution in the longitudinal and transverseedge beams of the modules. The two vertical perforated rolled shapes (1a, 1 b) function as compression members of the edge beam.

The three basic components of the edge beam are positioned so as toprovide access for the press joining tools. In particular, theconstruction of the edge beams permits automatic insertion of the toolhead so that the bottom flanges of the compression members can be pressjoined directly to the web of the bottom track (2) along the full lengthof the edge beam at precise locations and frequency to develop thevariable required shear loading resistance to bending moments of theedge beam.

As shown in FIG. 2, the edge beam's depth can be varied from 6″ to 14″and the width can be varied from 6″ to 12″ to accommodate various airduct sizes, required piping sizes, and drainage grades. The gages andlengths of the rolled shapes can be varied and connected by pressjoining and varying jointing of structural sections to accommodatevarying stresses within the same edge beam, thereby matching selectedgages to loading characteristics, minimizing the cost of steel materialsand enabling handling of shorter structural sections. These factorsnecessarily result in varied structural cross sections of the edge beam,as seen in FIG. 2. The particular cross section of the edge beam isdesigned to match the required strength characteristics of the edge beamto the stress variations occurring in the edge beam for the variousloads developed in the transporting frame assembly as seen in FIG. 7,the lifting strength required for setting modules, and the opening spansof the marriage and exterior walls. Note that the opening spans of themarriage and exterior walls can be reinforced with continuous verticalheader beams to accommodate architectural open glazed (large glassareas) design and open architectural planning between modules.

Floor panels (see FIG. 3), ceiling panels and roof panels are all framedin the transverse dimension between the edge beams of the panels withjoist systems (4) 2′-0″ on-center and supported with joist connectors orhangers (11) as shown in FIG. 6. The joist connectors extend across thetop of the edge beams and are assembled by press joining to secure thevertical members of the edge beam in place. This arrangement ties theupper ends of the vertical members together. Intermediate beams (IB) (5)and double joists (6) are anchored in similar fashion with connectors(FIG. 6) of a width to accommodate the transverse members. Theconnectors (11) are shaped for automated placement by a carousel, andare installed as the panel advances in a 4 ft stepped motion. Theconnectors (11) are provided with openings or perforations forpermitting mechanical and utility distribution to run from the interiorof the edge beam through the openings and into the transverse member.Note that cutouts are provided in the sides of the connectors to provideaccess for robotic welders to connect the connectors to the transversemembers.

The exterior and marriage wall panels (FIG. 4) are constructed of 6 inchminimum width wall studs of 20 gage galvanized steel and can beincreased in width and gage as building heights or floor and roofloadings increase. In the exterior and marriage walls, major structuralstuds (7) repeat every 4′-0″ on-center. The minor non-load bearing studs(8) are provided for sheathing stiffening and repeat an alternate 4′-0″on-center. All vertical loads of the modular structure are transferredto the foundation via the structural exterior and marriage wallstructural studs (7).

As shown in FIG. 1C, the major structural studs (7) are strengthenedwith galvanized steel plates (9) at the top attachment to the wallpanel's continuous header beam (10) and at the bottom attachment to thefloor panel. The triangular shaped reinforcement plates are press joinedto the studs during the structural fabrication of the wall panels. Thebottom plates are screwed to the floor panels during the module panelerection.

The construction of the continuous exterior and marriage wall headerbeam (10) is similar to the edge beam and intermediate beam fabricationexcept for the intermittent bottom track, which allows the wiringharnesses and piping that has been inserted through the open top, toconnect with electrical wiring and piping in the wall panels belowduring the module panel erection.

The continuous top wall header beam serves several unique functionsincluding horizontal shear resistance supplemental to the wall sheathingmaterials in the exterior and marriage wall panels, provision for anopen channel track for the insertion of metal assemblies to bolt and/ormechanically splice stacked modules together at varied locations as maybe required structurally, and an open space for unforeseen mechanicaland electrical systems.

The inversion of the two vertical perforated rolled shapes web membersallows foamed insulation to permeate the perforations and isolate thesteel web members from the inside surface of exterior and marriage wallsheathing material, thereby creating a nearly complete thermal break andinsulation of the structure.

The invention employing innovative light gauge steel module framingtechniques includes a method of automated manufacture. The method ispossible through the use of a programmed computer driven automatedsystem for module panel manufacture. The system directs the movement ofequipment and material employed in the manufacturing process. Theautomated system is capable of placing every structural member, sheetingmaterial and thermal insulation using the same manufacturing line tocreate floors, exterior and marriage walls, interior walls, ceilings,roofs and gables of varying lengths and widths in the order required formodule assembly.

The automated manufacturing line (FIG. 8) advances the light gauge steelframing assembly four feet after the completion of each stage on theframing table and assembly line. The various stages of the manufacturingprocess are described below.

Stage (1): Steel Shapes Roll-Formed

In this stage flat steel is loaded into purchased steel roll-formingmachinery to custom form and cut steel shapes in varied cross sectionsand lengths as needed. In addition, the roll-form machinery will cutaccess holes in the webs of the steel shapes as necessary.Alternatively, pre-formed transverse and longitudinal members can bepurchased from existing companies.

Stage (2): Overhead Crane Lifts Steel Shapes onto Framing Table Duringthis stage the crane lifts the steel shapes that are necessary for edgebeam construction of a particular panel and transports them to theframing table in preparation for the third stage.

Stage (3): Panel Edge Beam Members Loaded Onto Line

In this stage the edge beam components (1 a, 1 b) are manually placed inthe track (2) with the webs back-to-back, resulting in a placement ofthe components that is inverted relative to the typical box-beam memberplacement. This arrangement gives the press-joining equipment access tothe various connection points. Alternatively, the loading of the edgebeam components could be automated.

Stage (4): Edge Beam Components Press-joined to Form Edge Beam AssemblyIn this stage the flanges of edge beam members (1 a, 1 b) arepress-joined to the web of the track (2).

Stage (5): Placement of Steel Connectors (11) Over Edge Beam Assembly

In this stage a carousel selects the appropriate width, depth and gaugehanger and drops it on top of the edge beam assembly as shown in FIG. 1Aand in FIG. 6. Although providing proprietary access and fins forconnection, the connector cradle design functions similarly to a joisthanger in conventional construction.

Stage (6): Placement of Transverse Members into Steel Connectors (11)

In this stage an overhead automated hopper system places the transverseframing member into the connector cradles from above. Alternatively, thetransverse framing members could be placed manually.

Stage (7): Robots Weld Transverse Framing to Connectors

The fin of the connector and web of the transverse member are weldedtogether at two points. Alternatively, smaller press-joining machinerycould be developed to access and join the pieces.

Stage (8): Sheeting Conveyor and Vacuum Lifter Selects and ConveysAppropriate Sheeting Material

In this stage a vacuum lifter on a moveable framework will select andvacuum transport one sheet of material from the material stack onto aconveyor system. The conveyor transports the material to the sheetingpreparation machine in the ninth stage.

Stage (9): Material Advances through Sheeting Preparation Machine:

In this stage the material is conveyed through the sheeting preparationmachine and is punched and routed as required. As the material advances,adhesive is applied to the top of the sheeting in preparation for thetenth stage.

Stage (10): Sheeting Attached to the Bottom of Framing Members

In this stage the sheeting material is conveyed under the framingassembly and pressed up and adhesively joined to the framing members. Inaddition, fastening equipment such as automated screw guns or steel nailguns mechanically fasten the sheeting material to the framing membersfrom below the panel plane.

Stage (11): Transfer of Frame with Bottom Sheeting to a Conveyor Theframing assembly with bottom sheeting attached transfers to a conveyorsystem.

Stage (12): Installation and Pressure Testing of Pre-AssembledMechanical and Utility Systems

In this stage the mechanical and utility systems are fed through theholes in the transverse members and along the open edge beam channelfrom above. Once connections have been made between systems, theassembly is pressure tested for quality control.

Stage (13): Insulation Foamed into Structural Frame

In this stage the framing assembly, with attached lower sheeting andinstalled mechanical and utility systems, advances to a vapor controlarea and the void between members is insulated with expanding foamissued from nozzles mounted above the panel plane. The insulation caneither be a soy “bio-based” formulation or a traditional foam product.

Stage (14): Application of Adhesive to Top of Steel Framing Members

Nozzles above the panel plane lay a bead or coating of adhesive on topof the exposed members in preparation for the fifteenth stage.

Stage (15): Installation of Top Sheeting

After selection by a vacuum lifter and passing through the sheetingpreparation machine, as in stage 9, the sheeting material is lowered andpressed onto the adhesive applied in stage 14. In addition, mechanicalfastening equipment such as automated screw or nail guns mechanicallyfastens the sheeting material to the framing members from above thepanel plane.

Stage (16): Panel Advanced to Scissor Lift Supports The scissor liftsupports have a low-friction finish on a table top-like surface thatallows the panel to slide into position.

Stage (17): Floor Panel Lowered on Scissor Lifts In this stage the floorpanel (FIG. 3), when complete, is lowered slightly on scissor lifts.

Stage (18): Manufacture of Module Walls

In this stage, the module walls (FIG. 5) are manufactured in a processsimilar to the above. The interior walls (FIG. 5) are manufacturedtogether as one contiguous panel with top and bottom track web cut tolength and flanges left uncut before stacking on top of floor panel.Exterior and marriage walls (FIG. 4) are manufactured similarly andstacked on top of the interior wall panels. The stack including floorpanel, exterior and marriage wall panels, and interior wall panels isreferred to as the module base stack (MBS).

Stage (19): Insertion of Air-Casters Under MBS

In the nineteenth stage, air casters are inserted under the module basestack.

Stage (20): Module Base Stack Manually Floated on Air Casters to theModule Base Erection Bay

The module base erection bay contains an overhead hoist system, which isnecessary for the twenty first and twenty second stages.

Stage (21): Installation of Exterior and Marriage Walls

In this stage, the overhead hoist system lifts and rotates the exteriorand marriage wall panels into place before the wall framing is manuallyfastened, using screws or nails, to the floor panel using connectionplates.

Stage (22): Installation of Interior Walls

In this stage the interior walls are raised as a panel before the trackflanges are cut for each wall individually. The newly separated wallsare then mechanically fastened to the structure as needed. The completedstructure is referred to as the module base (MB).

Stage (23): Manufacture of Attic Floor, Gable and Roof Panels

Similar to stages 1-18 as described above, the attic floor, gable androof panels are manufactured and stacked as an attic stack (AS) on thescissor lift supports. Also, the first floor ceiling panels aremanufactured as single elements to complete first and intermittent floormodules.

Stage (24): Transport of the Attic Stack

In this stage the overhead crane transports the attic stack to the gableassembly bay. The gable assembly bay contains a large elevated worksurface and a sliding and pivoting diamond-blade saw. The overhead cranelifts the roof panels from the attic stack and the roof panels aretransported to the roof assembly bay. The roof assembly bay contains anelevated work surface, roofing materials and fastening equipment.

Stage (25): Assembly of the Roof

With the roof panels placed on the roof assembly bay elevated worksurface, removable lifting hinges with integral crane loops aremechanically fastened to the panels. After installation of the liftinghinges, roofing materials, such as shingles or architectural metal andany necessary trim, are applied.

Stage (26): Cutting of Gable by 80%

While assembly of the roof occurs, the gable panel in the gable assemblybay (GAB) is cut 80% through with the diamond-blade saw. The cutsdelineate the gable panel into four gable sections. The saw can bemanually or automatically positioned for this stage.

Stage (27): Installation of Steel Angle in Gable Cuts

In this stage, steel angles are mechanically fastened with one leg ofthe angle perpendicular to the plane of the panel with the legprojecting into the cuts made in stage 26, and the other leg parallel tothe plane of the panel resting on top of the sheeting material.

Stage (28): Application of Exterior Finish to Gable Sheeting andInstallation of Attic Vent

In this stage, an exterior finish, such as vinyl siding or afiber-cement siding product, is mechanically fastened to the gablesheeting. Additionally, an attic vent and any specified trim ismechanically fastened to the gable sheeting.

Stage (29): Overhead Crane Lifts and Rotates the Gable Panel

In this stage the overhead crane lifts the gable panel and rotates thepanel 180 degrees before replacing the gable panel on the attic floorpanel. The gable panel sheeting, with the exterior surface applied, isnow facing the floor with exposed framing facing the ceiling (upwardly).

Stage (30): Cutting Remaining 20% of Gable

In this stage the diamond-blade saw cuts through the remaining 20% ofthe gable panel, thereby separating the gable panel into four pieces(FIG. 10).

Stage (31): Installation of Steel Angle on Edges of Gable Pieces

Similarly to stage 27, steel angle is installed on the edges of thegable pieces.

Stage (32): Final Gable Positioning

As shown in FIG. 10, the four gable pieces are lifted, rotated, andmoved into place by workers and the overhead crane.

Stage (33): Attic Stack Re-Compiled

In this stage, the overhead crane lifts and transports the roof panel tothe gable and attic floor assembly bay and lowers the roof panel ontothe positioned gable pieces.

Stage (34): Installation of Roof Rollers and Gable Hinges

In this stage, a roof roller apparatus that was patented by the presentinventor (U.S. Pat. No. 6,705,051 B1) and roof hinges are mechanicallyfastened to the roof panel, gable pieces and attic floor panel. Thedisclosure of U.S. Pat. No. 6,705,051 is incorporated herein byreference.

Stage (35): Overhead Crane Transports and Lowers the Attic Stack

In this stage, the overhead crane lifts the attic stack and transportsit to the module erection bay. The module erection bay is as describedin Stage 20. The overhead crane lowers the attic stack onto theassembled module base which was constructed in stages 21 and 22.

Stage (36): Assembly of the Module

In this stage, the attic stack is mechanically fasten to the module baseand the mechanical and utility connections are hooked up between wall,floor and roof panels.

Stage (37): Assembled Module Advanced to Finishing Stations

In this stage, the assembled module is pushed on air casters to typicalfinishing stations for remaining exterior finishes, interior wall andfloor finishes, cabinetry, plumbing and electric fixture installationand finish trim. Alternatively, the module advance could be accomplishedautomatically.

Stage (38): Finished Module Ready for Transport Assembly Mounting andShipment

The module is referred to as a finished module after completion ofstages 1-37 and is now ready to be placed on a transport assembly andprovided with a module cover, which provides temporary surfaceprotection during shipment. The module is now ready to be shipped.

The novel module construction utilizes a light gauge steel framingsystem that incorporates press joining and robot welding of light gaugemetals. The structure and process accommodates the multi-directionalorientations required of application tools to fasten multiple members.The process is capable of producing complex composite structuralconfigurations that utilize the strength capabilities of light gaugesteel rolled shape members.

It is intended that the invention be defined by the claims appendedhereto, and their equivalents.

1. A method of manufacturing a gable of a housing module, the methodcomprising: providing a single panel; performing a first cuttingoperation which includes cutting the panel along predetermined cut linesapproximately 80% of the way through the panel; rotating the panel;cutting through the remaining 20% of the panel to form a plurality ofgable sections; relocating the sections to a final shipping position;and attaching, via hinges, the gable sections to roof panels.
 2. Themethod of manufacturing a gable of a housing module as claimed in claim1, further comprising installing steel angle in the cuts made after thefirst cutting operation, applying exterior finish to the gable facing,and installing an attic vent.